Assembly Module for Composite Wall and Method of Assembly

ABSTRACT

Systems and methods for constructing composite wall structures are described in which opposing faceplates are provided that define a transverse void. A plurality of through connector assemblies, which span the transverse void between the faceplates, are attached with the opposing faceplate. A connecting mechanism is applied to the through connector assemblies from an outside of at least one of the faceplates and attaches with portions of the through connector assemblies in the transverse void. The transverse void may be filled with a fill material after attaching the opposing faceplates with the plurality of through connector assemblies.

BACKGROUND OF THE INVENTION

The present subject matter is directed to assembly modules for compositewalls, and methods for constructing composite walls. The present subjectmatter is applicable to various forms of modular composite constructionand finds particular applicability in the construction ofsteel-plate-concrete (SC) wall systems.

Conventional concrete walls systems typically use reinforcing steel(rebar) within the concrete wall to improve the structuralcharacteristics of the concrete. However, in construction applicationswhere accelerated construction of large structures is desired, theintricacies of such construction techniques can prove to be inefficientfor a number of reasons, including the amount of time toassemble/disassemble formwork and place rebar, as well as the associatedrequirement for significant on-site activities.

SC modular walls, and other modularized construction assemblies, areexperiencing increasingly widespread use in various constructionapplications, including, for example, the construction of nuclear powerplants. The safe and rapid construction of nuclear power plants hasbecome a particularly critical concern with respect to providingalternative energy in countries around the world, including the UnitedStates.

Known systems for SC construction may include the use of internalframing that is welded to opposing plates. For example, a Bi-Steelprocess is known for use in certain applications using friction weldedtie bars. Such methods may include using faceplates with a thicknessbetween 5 to 20 millimeters, and a distance between the plates of 200 to700 millimeters. Other structures may also use a welded internal framethat is in turn welded to the external plates.

However, known systems that rely on welding of the internal supportframework do not satisfy all of the needs of current applications,including, for example, size requirements, structural integrity andefficiency of construction. Of particular concern are the requirementsfor skilled labor to perform the difficult, and/or intricate, field orshop welding procedures in a large scale construction project. Thesefactors can quickly become prohibitive and/or greatly increase the costand time of construction. Usage of large scale welding can also lead towarping and residual stresses, factors that can affect the structure'sstrength and function.

In order to effectively build large structures, such as new nuclearpower plants, in a timely manner, it is becoming increasingly importantto reduce the high labor cost and lengthy schedules typically associatedwith nuclear power plant construction. Such improvements are necessaryin order to allow nuclear power to become a more viable alternative tofossil fuels and other lower capacity alternative fuel sources.

Additionally, since construction of nuclear plants, and other largeconcrete structures, including nuclear waste processing/storagefacilities and other structures such as chemical weaponsdemilitarization facilities that are designed for blast and missileresistance, involve substantial reinforcing, concrete and other on-siteactivities, concerns must be addressed regarding the shortages ofskilled on-site construction labor and the associated higher costs thatwould be experienced with simultaneous construction of multiple largeprojects.

The present subject matter provides improvements in the use of modularstructural assemblies that may provide efficiencies, includingsimplified construction, cost savings, and structural integrity, in theconstruction of SC modular walls, and similar applications, that maybenefit from the use of prefabricated assembly modules in theconstruction of structures including composite walls, and the like.

SUMMARY OF THE INVENTION

The present subject matter includes systems and methods for constructingcomposite walls in a building including the preassembly of wall assemblymodules that include opposing faceplates and a plurality of throughconnector assemblies that attach with the faceplates. In embodiments,opposing faceplates may be attached with a plurality of throughconnector assemblies that span a transverse void between the faceplates,and may include applying the connecting mechanism from an outside of atleast one of the faceplates to attach with a portion of the throughconnector assembly. Through the use of applying mechanical fasteningmechanisms from an outside of a faceplate, several advantages can beachieved such as simplifying assembly, and limiting or avoiding theamount of work required in the transverse void. An assembled wall modulemay be transported to a construction site, and filled with a fillmaterial. Filling of the assembly module may be done at a position inwhich the assembly module will occupy in a finished building.

In embodiments, a tension of a connector assembly may be adjusted aspart of the assembly process of the assembly module, on-site beforefilling the assembly module with the fill material, and/or any timeafter the assembly module is filled with the fill material. Suchfeatures may provide advantages over other known systems, such as thosethat use conventional reinforced concrete construction, or other modularcomposite construction where internal frames are welded to faceplates.

In embodiments, an external connector may be attached with a throughconnector assembly on a side of the composite wall. Such externalconnectors may include baseplates and other structural devices used todistribute or support a load on the wall.

Embodiments may include engaging a connector assembly with a faceplate,such as by a male threaded portion of a connector assembly with a femalethreaded portion of a hole in at least one of the faceplates.

Embodiments may include placing a plurality of sleeves between opposingfaceplates and inserting rods through the sleeves. This may includeinserting the rods through a hole in one of the opposing faceplates,through the respective sleeve, and out of a hole in the other of theopposing faceplates. In other embodiments, a plurality of rods and/orsleeves may be fixedly attached to a first faceplate, and a secondfaceplate positioned with respect to the fixedly attached rods and/orsleeves.

Embodiments may include securing the rods and/or sleeves from an outsideof at least one of the opposing faceplates.

Embodiments may include an assembly module for a composite wall, theassembly module including opposing faceplates with a transverse voidbetween the faceplates. A plurality of though connector assemblies atleast partially spanning the transverse void may be included. Thethrough connector assemblies may be connected with at least one of theopposing faceplates, and include a securing mechanism that is configuredto attach a portion of the through connector assembly at least partiallyin the transverse void with the at least one faceplate from an outsideof the at least one faceplate.

Embodiments may include an intermediate plate positioned between theopposing faceplates and connected with at least one of the throughconnector assemblies.

In embodiments, the securing mechanism is a mechanical device such as,for example, complementary male and female threaded members, frictionsecured members, and the like. As described herein, mechanicalconnections include mechanisms that do not rely on a welding bond fortheir primary attachment. However, these mechanisms may includeincidental welding to facilitate module assembly, and the like.

In embodiments, a threaded portion of the connector assembly mayprotrude through holes in each of the opposing faceplates and be securedby nuts attached to the threaded portion of the connector assembly.Embodiments may include a second nut configured to be attached to thethreaded portion of the through connector.

In embodiments, at least one of the through connector assemblies mayinclude a sleeve between the opposing faceplates. Such sleeves may spana distance between the opposing faceplates, span a distance between oneof the faceplates and an intermediate plate, or span a portion of adistance between opposing faceplates.

In embodiments, at least one of the through connectors assemblies maypartially penetrate at least one of the faceplates and include astopping mechanism at an end of the through connector assembly thatpositions the connector assembly with respect to the faceplate.

Stopping mechanisms may include, for example, a portion of the connectorassembly with a larger diameter, a nut attached to a threaded portion ofthe through connector assembly, a collar on the sleeve, and the like.

In embodiments, at least one of the through connector assemblies mayinclude a sleeve with a female threaded portion and at least one of theopposing faceplates may include a hole substantially where at least onethrough connector assembly connects with the at least one faceplate. Thesecuring mechanism may include a bolt configured to be inserted throughthe hole in the faceplate and engaged with the female portion of thesleeve and optionally with the female threads in the faceplate.

In embodiments, the through connector assemblies may include rods orsleeves that traverse the transverse void.

In embodiments, the securing mechanism may be adjustable from an outsideof the assembly module after the securing mechanism is secured.

In embodiments, the faceplates may include, or be substantially formedfrom, sheets of material including through holes, and the securingmechanism may be configured to attach with a portion of the throughconnector assembly through the holes. In embodiments, faceplates may beformed from at least two plates that are held together and/or compressedvia a securing mechanism on one end of a through connector assembly.

In embodiments, the through connectors may be mechanically attached withthe faceplates substantially without welding of the through connectorsto the faceplates.

In embodiments, the transverse void may have a width greater than 28inches. Although smaller widths are also envisioned, there areadvantages derived from the disclosed structures and methods that areparticularly beneficial with respect to known methods in constructingwalls with widths greater than 29 inches.

In embodiments where a through connector assembly includes a rod housedwithin a sleeve, a clearance between the rod and the sleeve may be in arange of 1/64^(th) of an inch to ⅛^(th) of an inch. In otherembodiments, this range may be between 1/32^(nd) of an inch and ⅛^(th)of an inch. In other embodiments, this range may be between 1/16^(th) ofan inch and ⅛^(th) of an inch.

The enumerated ranges have been found to provide different benefits andtolerances with respect to assembly procedures of the rods and sleeves,as well as the assembly module itself. For example, by minimizing theclearance of the rod within the sleeve, the slip distance will beaccordingly smaller once the slip resistance of a pretensioned joint isovercome. However, in situations where manufacturing tolerances requireaccommodation for variation in the respective bore size and diameter,larger tolerances may be required, such as, for example, 1/16^(th) of aninch to ⅛^(th) of an inch. This may increase an efficiency of theassembly process by minimizing the need for replacement and/or forceableassembly procedures.

Embodiments may include a concrete fill material that substantiallyfills a transverse void in the assembly module. As used to herein, thetransverse void should be understood as the space between opposingfaceplates, even in circumstances where the space is filled with a fillmaterial. In embodiments, the faceplates may consist essentially ofsteel plate material.

Embodiments may include means for connecting the faceplates across thetransverse void, and means for adjusting a tension of said means forconnecting after the transverse void is filled with a fill material.Embodiments may include means for adjusting a tension of said means forconnecting before the transverse void is filled with the fill material.Embodiments may include means for transmitting an attachment load froman exterior portion of one faceplate to an exterior portion of anopposite faceplate.

Embodiments may include means for reducing a stress concentration of anattachment load from an exterior portion of one faceplate.

Further advantages of the present subject matter will be apparent tothose of ordinary skill in the art upon reading and understanding thefollowing detailed description of preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an exemplary method in accordance with an embodiment ofthe present invention;

FIG. 2 depicts an exemplary wall assembly module in accordance with anembodiment of the present invention;

FIG. 3 depicts aspects of an exemplary wall assembly module inaccordance with an embodiment of the present invention;

FIG. 4 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 5 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 6 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 7 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 8 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 9 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 10 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 11 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 12 depicts aspects of an exemplary through connector assembly inaccordance with an embodiment of the present invention;

FIG. 13 depicts aspects of an exemplary assembly module in accordancewith an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is provided with reference toexemplary embodiments for the ease of description and understanding.Applicants' invention is not limited to the disclosed embodiments, andencompasses other variations that fall within the overall scope ofdescription provided herein.

The following exemplary method is described with reference to FIG. 1.The method may begin with S1000 and proceed to S1100 in which at leasttwo faceplates are provided. Faceplates may include, for example, steelplates with prefabricated through holes used for securing throughconnector assemblies. The through holes may be threaded or bare wallsdepending on the particular configuration of the securing mechanism forthe connector assembly. The plates may be, for example, ⅜^(th) of aninch steel plates. Depending on the method of assembling the assemblymodule, the faceplates may be provided and placed at the same time, or afirst faceplate provided and partially assembled with the connectorassemblies before providing and positioning a second faceplate. Inembodiments, one or more of the faceplates may include a plurality ofstacked plates, and/or one or more intermediate plates may be placed orpositioned between the opposing faceplates.

In embodiments, the opposing faceplates may be vertically positioned andsecured for assembly. In other embodiments, a first faceplate may belaid horizontally for assembly before positioning the second faceplate.After the one or more plates are positioned in S1100, the method mayproceed with S1200.

In S1200, portions of connector assemblies may be positioned withrespect to faceplates that have been positioned in S1100. This mayinclude, for example, positioning sleeves, rods, and the like, betweentwo vertically positioned faceplates. Alternatively, but notexclusively, individual sleeves, rods, and the like, may be positionedwith respect to a horizontally placed faceplate. In general, connectorassemblies may include, for example, combinations of sleeves, rods, andthe like, positioned between opposing faceplates and/or intermediateplates between the faceplates.

After a plurality of the portions of the connector assemblies arepositioned with respect to the plates, the method may continue withS1300.

In S1300, portions of the connector assemblies that have been positionedmay be secured to one or more faceplates, and/or intermediate plates.Various configurations for the securing mechanisms will be describedfurther below. By way of example, in circumstances where two opposingfaceplates are positioned vertically, with sleeves for the connectorassemblies placed between the faceplates, and rods running through thesleeves and holes in the opposing faceplates, the rods may be secured toan outer portion of the faceplates by attaching, for example, a nut to athreaded end of the rods. It should be noted that embodiments mayinclude where particular connector assemblies are configured to besecured with differently configured mechanisms at opposite ends. Forexample, one end of a through connector assembly may receive a boltthrough the faceplate, whereas the opposite end of the through connectorassembly may be engaged with the opposite faceplate, and/or a nutexternal to the faceplate, via threading on the connector assembly holein the opposite faceplate, and/or the nut. Alternative securing meansmay be beneficial in circumstances where the assembly process isdifferent for different sides of the assembly module, for example, ifthe first faceplate is assembled with the through connector assembly ina horizontal position, it may be advantageous to use methods in whichthe through connector assembly is fixedly engaged with the faceplateitself, whereas the second faceplate may be attached though a moreexpedient method that only involves turning an accessible portion of theconnector assembly, e.g., a bolt through the second faceplate.

In embodiments, a connecting mechanism may be applied from an outside ofat least one of the faceplates to attach with portions of the throughconnector assemblies that are at least partially in the transverse void.As discussed herein, through connector assemblies may include portions,contiguous or non contiguous, that traverse, or partially traverse, thetransverse void, as well as portions that extend partially, or fully,through one or more through holes in faceplates and intermediate plates.Connecting mechanisms described herein may be advantageous in assemblyprocesses by reducing the amount of work that needs to be done in thetransverse void, as well as allowing for adjustments in tension of thethrough connector assemblies. For example, during S1300, apre-tensioning of the through connector assembly may be accomplished,for example, by adjusting a thread engagement of a securing mechanism.The appropriate amount of pretensioning can vary significantly dependingon factors such as, for example, the diameter and material of the bolts,and structural characteristics of securing mechanisms, etc.Pretensioning the assembly may be advantageous in the circumstance wherethe assembly module is transported and/or lifted prior to placement andfilling.

In embodiments where the through connector assemblies are first securedto a first faceplate, such as in a horizontal orientation, a secondfaceplate, or intermediate plate may be positioned after securing theconnectors to the first faceplate. For example, a second faceplate maybe positioned according to a subset of the plurality of throughconnector assemblies, such as on the four corners, that are configuredto extend beyond the rest of the attached through connector assemblies.This may be done by extending internal rods or external sleeves, orelongated collars, beyond the length of the rest of the throughconnector assemblies. By using the subset of the through connectorassemblies, the second plate may be accurately positioned without havingto perfectly align all of the through connector assemblies withcorresponding holes. After the second plate is properly positioned withrespect to the subset of through connector assemblies, the remainingthrough connector assemblies may be individually adjusted, if needed,with respect to the corresponding through hole in the second plate.

After sufficient connections are made between the opposing faceplates,any intermediate plates, and/or the plurality of through connectorassemblies, the method may continue to S1400.

In S1400, the assembly module may be positioned in a location forfilling. This may include, for example, transporting the module from anassembly location to a worksite where a building is being manufactured.In a preferred embodiment, the module may be placed in a positionsubstantially where it will be located in the completed structure. Inembodiments, the module may be connected with other assembly modulesprior to, or after, filling. In embodiments, end plates may be providedto allow for the independent filling of the individual assembly module.This may be done as part of an initial assembly process, or it may beperformed at the on-site location.

During S1400, a tension of at least one of the through connectorassemblies may be checked and/or adjusted to accommodate a desiredpre-fill tension. This may allow for different tensions for transportand filling of the assembly module. After the assembly module ispositioned for purposes of filling and any desired pre-tensioning isperformed, the method may continue with S1500.

In S1500, the assembly module may be filled with a fill material.Examples of appropriate fill material may include, for example,concrete, and the like, such as, self-consolidating concrete, greenconcrete consisting of cement substitutes, fiber-reinforced concrete,etc. In embodiments that address the requirements of nuclear powerfacilities, concrete may be used to provide sufficient radiationshielding, and structural integrity that will withstand heat, force andother requirements of such specialized applications. After the assemblymodule is filled, or partially filled, the method may continue withS1600.

In S1600, a post-tensioning of the connector assemblies may beperformed. This may be done, for example, after filling at least aportion of the transverse void with the fill material. In embodiments,the through connector assemblies may be post-tensioned after concretehas cured and gained its sufficient strength to sustain post-tensioningstresses. Such post-tensioning can reduce concrete cracking, especiallyunder severe loads (e.g. earthquake induced loads) and improve the wallstrength.

In addition to the above processes, it is an advantage of aspects of thedisclosed subject matter that, according to embodiments, an externalconnector may be easily connected via exemplary through connectorassemblies. Thus, an external connection may be made before, during, orafter filling of the assembly module. For example, aspects of thepresent subject matter provide an easy way to add attachments to acomposite wall, after filling of the wall, by completely or partiallyremoving an external connector from the wall, that is connected with athrough connector assembly, and attaching an external connector to thethrough connector assembly. For example, in embodiments that use athrough rod that penetrates the faceplate and engages with a throughconnector assembly, the nut(s) at the rod end may be removed, a baseplate placed on the faceplate, and the nuts restored. Such methods areeasily accomplished, and provide improved structural integrity that isbuilt into the wall and through the wall. They also eliminate the needfor direct welded attachment to an individual faceplate or need fordrilling new holes in the same to install anchor bolts.

Such mechanisms that attach an external connector to a through connectorassembly may provide, for example, means for transmitting an attachmentload from an exterior portion of one faceplate to an exterior portion ofan opposite faceplate, and means for reducing a stress concentration ofan attachment load from an exterior portion of one faceplate.

After the assembly module is filled to an acceptable level, and adesired post-tensioning is completed, the method may proceed with S1700where the method is complete.

Further structural details regarding an exemplary assembly module arediscussed with reference FIG. 2. As show in FIG. 2, opposing faceplates210, 212 may be configured with through holes 220, 222. In embodiments,through holes 220, 222 may be similarly configured as smooth walledholes, or threaded holes. In the embodiment depicted in FIG. 2, forexample, the through holes 220, 222 may be smooth walled holes. In otherembodiments, the through holes may be differently configured to allowfor different attachment mechanisms on either side. Sleeves 230 may bepositioned between the opposing faceplates. Rods, e.g. 240, may beinserted through holes 220, sleeves 230 and through holes 222. Inembodiments, ends of rod 240 may be threaded and rod 240 may be ofsufficient length to protrude beyond both of exterior surfaces offaceplates 212 and 210. Securing mechanisms, such as, for example nuts,250 may be attached to ends of rods 240.

Configurations such as those depicted in FIG. 2 may provide for anassembly process that is easy for unskilled labor and/or capable ofautomation by simplifying the attachments with opposing faceplates,without the need for complicated welding, and/or work within thetransverse void. For example, the faceplates 210, 212 may be positionedvertically and secured. A moveable rack system may then be used to placeone or more rows of sleeves 230 in appropriate positions with respect tothrough holes 220, 222. With the sleeves 230 appropriately positioned,rods 240 may be inserted from one side of the assembly module to theother. The exposed ends of rod 240 may then be secured from eitherexterior side of the assembly module via appropriate securing means. Thesleeves 230 may provide advantageous support in restraining thefaceplates 210, 212 from caving in during pre and post-tensioning actionof the through connector assemblies.

In alternative embodiments, a first faceplate, similar to faceplate 212,may be provided and portions of through connector assemblies secured tothe first faceplate prior to positioning a second plate, such asfaceplate 210. A subset of the through connector assemblies may be usedto accurately position the second faceplate.

Additionally, as discussed further below, through holes such as 220, 222may be threaded in order to allow positive engagement of a sleeve, rod,bolt, or the like, with the faceplate.

As discussed above, an assembly module, such as depicted in FIG. 2, maybe filled with a filling material, such as concrete, and provide aportion of a composite wall, as shown in FIG. 3. It should be notedthat, complete or partial filling of the assembly module may beperformed prior to moving the assembly module to the constructionlocation, or placement location, for the module. For example, a portionof the assembly module may be filled prior to moving the assembly moduleto the construction site. This may be advantageous in circumstanceswhere weather, temperature, or other environmental or other factors makefilling of the assembly modules at the construction site problematic.Partial or complete filling may also provide advantages in handling andtransportation characteristics as well.

As shown in FIG. 3, a composite wall assembly 300 may include opposingfaceplates 310, 312, and connector assemblies including securingmechanisms 320. The composite wall assembly 300 may also includetransverse walls (not shown) that help form the extent of the voidfilled by the fill material. In embodiments, an external connector, suchas base plate 330, may be attached via the through connector assembliesand securing mechanisms. The composite wall assembly may includemultiple assembly modules that are stacked or otherwise arranged to forma structure. Although depicted in a substantially box-likeconfiguration, the present subject matter is applicable to variouslyshaped assembly modules and structures and can form myriad shapes andsizes. For example, a plurality of arced assembly modules may beassembled to form complete or partially ring-shaped walls. The assemblymodules can be joined to one another by ways known to those of skill inthe art, and are not discussed at length herein. Such methods mayinclude welding of the seams of adjacent assembly modules, or usingbolted joining means.

In embodiments, a width W of the wall assembly may be greater than 29inches. Such thicknesses may be useful in specialized constructionapplications, such as walls of nuclear facilities that require radiationshielding as well as significant structural strength. In embodiments, anintermediate plate 340 may also be provided in the wall assembly 300.Intermediate plates may also be useful in providing improved fireresistance, and improved resistance to blast, missiles and the like. Fortransportation purposes, the L of an individual module may beapproximately 60 feet or less to allow a module to be transported on astandard flatbed truck. Likewise, an exemplary H for a module may beapproximately 12 feet or less. Of course, modules of greater size thanthe exemplary dimensions provided are also possible within the scope ofthe invention. Additionally, instead of placing assembly modulesindividually, a plurality of assembly modules may be joined together ata construction site and moved together, such as by crane, to a desiredplacement.

Aspects of an exemplary connector assembly including a securingmechanism are depicted in FIG. 4. As show in FIG. 4, a sleeve 410 may beprovided that abuts a faceplate 420. Direct contact of the sleeve 410with the faceplate 420 is not required and may be accomplishedindirectly via washers and other intermediate shimming elements. A rod430 is housed within the sleeve 410 and extends through the faceplateelement 420 and a second faceplate element 422. Unlike some of the knownsystems, the present subject matter provides for easy and structurallysecure ways to use stacked plates as a faceplate, as shown in FIG. 4.Forming a faceplate from a combination of thinner plates may beadvantageous for a number of reasons including, for example, theavailability of thinner steel plate and the like. Between the rod 430and sleeve 410 is a clearance 435. In embodiments, this clearance may bein a range of 1/64^(th) of an inch to ⅛^(th) of an inch. In otherembodiments, depending on the tolerances of the sleeve 410 and rod 430,the clearance 435 may be in a range of 1/32^(nd) or 1/16^(th) to ⅛^(th)of an inch. As depicted in FIG. 4, the faceplate 420 includes a throughhole 440 through which the rod 430 extends. The rod 430 is secured tothe faceplate 420 via threaded nut 450 and washer 460. By tightening thenut 450, compression of the faceplate 420 between the washer 460 andsleeve 410 and/or a tension in the rod 430 may be suitably adjusted.

Aspects of an additional exemplary connector assembly including asecuring mechanism are depicted in FIG. 5. As shown in FIG. 5, a sleeve510, may include a threaded end 515 that abuts a faceplate 520.Faceplate 520 includes a through hole 525 that may be threaded topositively engage a bolt 530 that penetrates the faceplate 520 andpositively engages with sleeve 510 via female threaded area 515. Inembodiments, a bolt shank length sufficient to add a 1 inch to 2 inchbase plate may be used. It should also be noted that the hole infaceplate may be smooth with a slight oversize ( 1/32″ to ⅛″ excessdiameter relative to the bolt diameter).

A base plate 540 may be secured via washer 560 and bolt 530. Thus,external forces applied to a connector such as base plate 540 may betransmitted via bolt 530 to a through connector assembly includingsleeve 510.

Aspects of an additional exemplary connector assembly including asecuring mechanism are depicted in FIG. 6. As shown in FIG. 6, a rod 610with threaded end 615 may penetrate a faceplate 620. Rod 610 may bepositioned with respect to the faceplate 620 from an inside of thefaceplate via a nut 630 and washer 640 that may act as a stoppingmechanism when the rod is positioned in the through hole 625. On theexterior of faceplate 620, the rod 610 may be secured by one or morethreaded nuts 650, 660 and washer 670. In embodiments, when a rod 610 isattached to a faceplate 620 in the matter depicted in FIG. 6, anopposite end of the through connector assembly may be advantageouslysecured to the opposite faceplate in a different manner. For example, amale threaded end of rod 610 may be engaged with a female threadedcoupling nut that abuts an opposite faceplate. A bolt that penetratesthe opposite faceplate may be positively engaged with the collar andsecure the through connector assembly to the opposite faceplate. Anexample of the described opposite mechanism may be seen, for example, inFIG. 10. By using different securing mechanisms for opposite ends of thethrough connector assembly, the through connector assembly can bepost-tensioned in ways that are not possible by using two attachmentssuch as depicted in FIG. 6.

Aspects of an additional exemplary connector assembly including asecuring mechanism are depicted in FIG. 7. As shown in FIG. 7, a rod 710penetrates a faceplate 720. Rod 710 may include a stopping mechanismsuch as the formed protrusion 715 that positions the rod 710 withrespect to the faceplate 720. A threaded end 716 of rod 710 may bepositively engaged with a threaded though hole 722 of the faceplate 720and secured with a threaded nut 730 and washer 740. Through the use ofthreaded engagement in the nut 730, distribution by washer 740, andthreaded engagement with the through hole 722, an exemplary means fortransmitting an attachment load from an exterior portion of an oppositefaceplate of an exterior portion of faceplate 720 may be achieved. Aswith the embodiment depicted in FIG. 6, an opposite end of the throughconnector assembly depicted in FIG. 7 may be advantageously secured tothe opposite faceplate in a different manner than that shown in FIG. 7.

Aspects of an additional exemplary connector assembly including asecuring mechanism are depicted in FIG. 8. As shown in FIG. 8, a sleeve810 may abut a faceplate 820. A rod 830 may be housed in the sleeve 810and penetrate the faceplate 820. A mechanical connection, such as aseizing ring 840 and washer 850 may be used to fixedly secure the rod830 at a position with respect to the faceplate 820. The surface of rod830 may be contoured or otherwise configured to improve the ability ofseizing ring 840 to secure the rod 830 in position.

Aspects of an additional exemplary connector assembly including asecuring mechanism are depicted in FIG. 9. As shown in FIG. 9, a sleeve910 with threaded portion 912 may be positively engaged with a threadedthrough hole 922 of faceplate 920. A securing mechanism, such as a blindflange 930, may be positively engaged with the male threads of threadedportion 912 via female threaded portion 932. Thus, as show in FIG. 9,the sleeve 910 is positively engaged with both of the faceplate 920 andblind flange 930. In alternative embodiments, a blind flange, such as930, may be used to provide a means for pre and/or post-tensioning athrough connector assembly via a threaded portion of a sleeve and/or rodby using a smooth through hole in a faceplate that does not positivelyengage the sleeve and/or rod. In embodiments, first through connectorassemblies may be used, or configured, to provide tensioning capability,whereas second through connector assemblies may be fixedly attached, tomaintain appropriate distances and the like. An elbow drain may also beused in lieu of blind flange 930. By using elbow drains, drainage fromsleeve 910 may be achieved, while limiting ingress in a controlledmanner.

Aspects of an additional exemplary connector assembly including asecuring mechanism are depicted in FIG. 10. As show in FIG. 10, a rod1010 is engaged via male threads with a female threaded portion ofcollar 1020, a gap 1030 is maintained between an end of the rod 1010 andof through bolt 1040. The through bolt 1040 may be positively engagedwith the threads of collar 1020. Through bolt 1040 may secure a throughconnector assembly to the faceplate 1050 via washer 1060 and collar1020. By way of example, a coupling nut 1020 may be provided in a lengthof 4 inches, 6 inches or 8 inches. Such lengths have been found to besufficient for structural integrity when combined with rods andattachment assemblies, and also to provide desirable adjustability inwall assembly modules to permit external connector attachments such asfor example 1 inch to 2 inch baseplates. A distance of approximately⅛^(th) of an inch or greater may be present in gap 1030. These types ofattachments may be useful for a number of reasons, particularly withrespect to modular wall components used in the construction of nuclearfacilities. For example, if open pipes are used substantially throughoutthe length of the through connector assembly, there can be problems withadequate radiation shielding. As such, although the use of through boltsand hollow pipes have been discovered to be efficient mechanisms forsecuring the through connector assemblies, there may be a need tointegrate sufficient radiation protection along with this attachmentmechanism. The inventors have found that an efficient way ofincorporating the benefits of a hollow sleeve, at least at one end ofthe through connector assembly, is to use a collar along with a threadedrod. Such an assembly allows for an easy and adjustable connection pointat one end of the through connector assembly, while maintaining asubstantially solid wall throughout the length of the through connectorassembly.

FIG. 11 depicts aspects of an exemplary assembly module for compositewall construction according to an embodiment of the present invention.As shown in FIG. 11, opposing faceplates 1110 and 1120 may be connectedwith a bar 1140. The assembly module may also contain an intermediateplate 1130 through which the bar 1140 passes. It should be noted that,in embodiments, connector assemblies may be connected with anintermediate plate, or passed through the intermediate plate. A sleeve1150 is placed between the faceplate 1110 and intermediate plate 1130,and a sleeve 1160 is placed between intermediate plate 1130 andfaceplate 1120. Threaded ends of the bar 1140 are positively engagedwith threaded nuts 1170 and 1180. Washers 1172 and 1182 may also be usedto assist in distribution of a load applied by or through the connectorassembly to the faceplates 1110 and 1120. Additionally, the faceplates1110 and 1120 may act as a further means for distributing a load byapplying force to an extent of a fill material in transverse void 1190.Additional intermediate plates, similar to 1130, may be placed betweenfaceplates 1110 and 1120.

Such a configuration is usable, for example, in an assembly module asdepicted in FIG. 2, and lends itself to the process of (1) verticallyplacing the faceplates, and any intermediate plates, (2) placing thesleeves in the appropriate positions between the plates, and (3)inserting the rods through the plates and the sleeves. The ends of therod can then be easily secured from an outside of the assembly module.

FIG. 12 depicts aspects of another exemplary assembly module forcomposite wall construction according to an embodiment of the presentinvention. As shown in FIG. 12, faceplates 1210 and 1220 are connectedwith a bar 1230, coupling nut 1240, and bolt 1250. In the exampledepicted in FIG. 12, the bar 1230 may be positively engaged with femalethreads of through hole 1222 and faceplate 1220. Bar 1230 may be furthersecured by female threads in the nut 1224, and washer 1226. An oppositeend of the bar 1230 may also be threaded and engaged with female threadsof collar 1240. Threads of the collar 1240 may also be engaged withthreads of through bolt 1250 to secure the through connector assembly tothe faceplate 1210. A gap 1244 may be maintained in the collar to allowfor adjustment of the through connector assembly.

As indicated previously, individual through connector assemblies may beattached with an intermediate plate without passing through the fulldistance of a transverse void. For example, as depicted in FIG. 13, aconnector assembly 1340 may be attached with a faceplate 1310 andintermediate plate 1320. Another connector assembly 1350 may beconnected with intermediate plate 1320 and 1330. This configurationdepicted in FIG. 13 may be useful in applications that requireadditional fire, blast, and/or missile resistance, as well as providingimproved strength for handling, transportation, erection, and concreteplacement. Such a configuration may also be simple to assemble withoutrequiring collinear sleeve placement in adjacent portions of thetransverse void.

The invention has been described with reference to exemplaryembodiments. Modifications and alterations of the described embodimentsmay be evident to those of ordinary skill in the art upon a reading andunderstanding of the specification. The present invention is intended toinclude also such modifications and alterations in so far as they comewithin the scope of the appended claims, or the equivalents thereof.

1. An assembly module for a composite wall, the assembly modulecomprising: opposing faceplates with a transverse void between saidfaceplates; a plurality of through connector assemblies at leastpartially spanning the transverse void and connected with at least oneof the opposing faceplates, said through connector assemblies includinga securing mechanism that is configured to attach a portion of theconnector assembly in the transverse void with the at least onefaceplate from an outside of the at least one faceplate.
 2. The assemblymodule of claim 1, further comprising at least one intermediate platepositioned between said opposing faceplates and connected with at leastone of said through connector assemblies.
 3. The assembly module ofclaim 1, wherein said securing mechanism is mechanical.
 4. The assemblymodule of claim 1, wherein: a threaded portion of the connector assemblyprotrudes through holes in each of the opposing faceplates; and saidsecuring mechanism includes a nut configured to be attached to thethreaded portion of the connector assembly.
 5. The assembly module ofclaim 4, said securing mechanism further comprising a second nutconfigured to be attached to the threaded portion of the throughconnector.
 6. The assembly module of claim 1, wherein: a male threadedportion of at least one of the connector assemblies is engaged with afemale threaded portion of a hole in at least one of the faceplates. 7.The assembly module of claim 1, wherein at least one of the throughconnector assemblies comprises a sleeve between the opposing faceplates.
 8. The assembly module of claim 7, wherein said sleeve defines adistance between the opposing faceplates.
 9. The assembly module ofclaim 7, wherein said sleeve defines a distance between one of thefaceplates and an intermediate plate.
 10. The assembly module of claim1, wherein: at least one of the through connector assemblies penetratesat least one of the faceplates; and the at least one through connectorassembly includes a stopping mechanism at an end of the throughconnector assembly that positions the connector assembly with respectthe at least one faceplate.
 11. The assembly module of claim 10, whereinsaid stopping mechanism includes a nut attached to a threaded portion ofthe through connector assembly.
 12. The assembly module of claim 1,wherein: at least one of the through connector assemblies includes asleeve with a female threaded portion; at least one of the opposingfaceplates includes a hole substantially where the at least one throughconnector assembly connects with the at least one faceplate; and thesecuring mechanism includes a bolt configured to be inserted through thehole in the at least one faceplate and engaged with the female threadedportion of the sleeve.
 13. The assembly module of claim 1, wherein thethrough connector assemblies include at least partially threaded rodsthat traverse the transverse void.
 14. The assembly module of claim 1,wherein the through connector assemblies include at least partiallythreaded sleeves that traverse the transverse void.
 15. The assemblymodule of claim 1, wherein the securing mechanism is adjustable from anoutside of the assembly module after the securing mechanism is secured.16. The assembly module of claim 1, wherein the faceplates comprisesheets of material including through holes, and said securing mechanismis configured to attach with said through connectors through saidthrough holes.
 17. The assembly module of claim 1, wherein said throughconnectors are mechanically attached with the faceplates substantiallywithout welding of said through connectors to the faceplates.
 18. Theassembly module of claim 1, wherein the transverse void has a widthgreater than 29 inches.
 19. The assembly module of claim 1, furthercomprising a concrete fill material that substantially fills thetransverse void, wherein, said faceplates consist essentially of steelplate material.
 20. An assembly module for composite wall comprising:opposing faceplates with a transverse void between said faceplates;means for connecting said faceplates across the transverse void; andmeans for adjusting a tension of said means for connecting after thetransverse void is filled with a fill material.
 21. The assembly ofclaim 20, further comprising: means for adjusting a tension of saidmeans for connecting before the transverse void is filled with the fillmaterial.
 22. The assembly of claim 20, further comprising: means fortransmitting an attachment load from an exterior portion of onefaceplate to an exterior portion of an opposite faceplate.
 23. Theassembly of claim 20, further comprising: means for reducing a stressconcentration of an attachment load from an exterior portion of onefaceplate.
 24. A method of constructing a composite wall comprising:providing opposing faceplates; attaching the opposing faceplates with aplurality of through connector assemblies that span a transverse voidbetween the faceplates including applying a connecting mechanism from anoutside of at least one of the faceplates to attach with portions of thethrough connector assemblies in the transverse void; and filling thetransverse void with a fill material after attaching the opposingfaceplates with the plurality of through connector assemblies.
 25. Themethod of claim 24, wherein the connecting mechanisms is adjustablyconnected with the through connectors.
 26. The method of claim 24,further comprising: after filling at least a portion of the transversevoid with the fill material, adjusting the connecting mechanism suchthat a tension of at least one of the through connectors is changed. 27.The method of claim 24, further comprising: before filling thetransverse void with the fill material, adjusting the connectingmechanism such that a tension of at least one of the through connectorsis set to a desired tension.
 28. The method of claim 24, furthercomprising: attaching an external connector with at least one of thethrough connectors via the connecting mechanism.
 29. The method of claim24, wherein attaching the opposing faceplates with a plurality ofthrough connector assemblies includes: placing a plurality of sleevesbetween the opposing faceplates; for each of the plurality of sleeves,inserting a rod through a hole in one of the opposing faceplates,through the respective sleeve, and out of a hole in the other of theopposing faceplates; and securing the rods from an outside of at leastone of the opposing faceplates.
 30. The method of claim 24, whereinattaching the opposing faceplates with a plurality of through connectorassemblies includes engaging a male threaded portion of at least one ofthe connector assemblies with a female threaded portion of a hole in atleast one of the faceplates.
 31. A method of constructing a compositewall in a building comprising: providing a pre-assembled wall assemblymodule including at least two opposing faceplates, and a plurality ofthrough connector assemblies attached with said faceplates; placing thepre-assembled wall assembly module in a position that the wall assemblymodule will occupy in the building; after the pre-assembled wallassembly module occupies the position, filling a transverse void betweensaid faceplates with a fill material; adjusting a tension of at leastone of said through connector assemblies after the transverse void isfilled with the fill material at least to a height of the at least onethrough connector assembly.
 32. The method of claim 31, wherein saidadjusting the tension of the at least one through connector assemblyincludes adjusting a threaded portion of a connecting device engagedwith a sleeve of the at least one through connector assembly.
 33. Themethod of claim 31, further comprising: attaching an external connectorwith at least one of the through connectors via a connecting mechanismon one side of the composite wall; and attaching the external connectorwith at least one load distributing device on an opposite exterior sideof the composite wall via the at least one through connector.